Waveguide assembly comprising a molded waveguide interface having a support block for a launch transducer that is coupled to a communication device through a flange attached to the interface

ABSTRACT

A waveguide interface comprising a support block configured to support a printed circuit board assembly. An interface is coupled to an end portion of the support block and extends from the support block. The interface includes a slot positioned to receive at least a portion of the printed circuit board assembly and one or more holes positioned to receive attachment devices to secure the interface to a waveguide component. The support block and interface are molded as a monolithic device. A method of forming the waveguide interface, a waveguide assembly including the waveguide interface, and a method of making the waveguide assembly including the waveguide interface are also disclosed.

This application is a continuation of U.S. patent application Ser. No.14/803,652 filed on Jul. 20, 2015, now U.S. Pat. No. 9,893,406 issuedFeb. 13, 2018, which is a continuation-in-part of U.S. patentapplication Ser. No. 13/383,203 filed on Jan. 9, 2012, now U.S. Pat. No.9,088,058 issued Jul. 21, 2015, which is a national phase filing under35 USC 371 of International Application No. PCT/US2010/046028 having anInternational Filing Date of Aug. 19, 2010, which claims the benefit ofpriority based on U.S. Provisional Patent Application Ser. No.61/235,245, filed on Aug. 19, 2009, each of which is incorporated hereinby reference in its entirety.

FIELD

The present disclosure relates generally to microwave and millimeterwave radio frequency waveguide assembly technologies. More specifically,the present disclosure relates to microwave and millimeter wave radiofrequency waveguide interface technologies, including waveguideinterfaces manufactured using injection molding techniques.

BACKGROUND

As the semiconductor industry continues to increase circuit complexityand density by reduction of process node geometries, operating signalfrequencies continue to increase. It is now possible to obtainsemiconductors that operate well into the millimeter wave region ofradio spectrum (30 GHz to 300 GHz). Traditionally, the types ofsemiconductors used have been in the category of “III-V” types,indicating that the semiconductor compounds have been derived fromperiodic table elements in the third and fifth columns, such as galliumarsenide (GaAs) and indium phosphide (InP). In recent years, lessexpensive semiconductor processes that arise from column IV of theperiodic table, such as silicon (Si) and germanium (Ge) have beenproduced in silicon CMOS (complementary metal oxide semiconductor) andsilicon germanium (SiGe) compounds. The result has been to extend theoperating frequency of low-cost silicon semiconductors well into the 60to 80 GHz range of frequencies. The availability of low-costsemiconductor technology has put pressure on millimeter wavemanufacturers to bring the overall costs down for the electromechanicalsupport mechanisms that enable these semiconductor devices.

Commercial waveguide structures enable low-loss energy transfer atmillimeter wave frequencies, with the additional benefit ofstandardization of size and mechanical coupling flange designs. Thestandardized sizes and coupling flanges enable interoperability betweendifferent devices and different manufactures, providing maximalflexibility for millimeter wave system design.

Traditional methods for interfacing semiconductor devices within amechanical waveguide have been to either provide a split-cavity type ofassembly with expensive precision machining requirements or to coupleenergy from an orthogonal planar printed circuit launch probe withassociated lossy energy transfer. With new semiconductor designsproviding balanced transmission line outputs, there has been nostraightforward electromechanical method for coupling millimeter waveenergy from the balanced outputs directly to a waveguide without addedcircuitry, such as a balun transformer, which also exhibits excessivelosses as the frequency range of operation increases.

The prior art methods for coupling energy into and out of semiconductordevices, as set forth above, can be divided into two categories. Thefirst category involves the use of split-cavity metallic structures thatallow the semiconductor chip to be placed into one of the cavities, withthe other half of the cavity then brought together with the first halfin a precision fit. The typical precision required for the internaldimensions of a millimeter wave waveguide is on the order of ±0.001″(0.025 mm). Obtaining this level of precision in the construction ofboth upper and lower cavity halves of a split cavity metallic structurethrough machining while maintaining registration alignment for such anassembly is expensive.

The second category used for coupling energy in and out of semiconductordevices is to provide a printed circuit board with a stub or paddleenergy launch. The stub or paddle launch is orthogonal to the waveguidecavity, also requiring a split-cavity type of assembly method, creatingadditional expense.

In each case, a custom, highly precision machining process is requiredto maintain the internal waveguide dimensional requirements. Some costreduction can be afforded through a casting process, but secondarymachining operations are still necessary to realize the precisionneeded.

The above prior methods also are designed for single-ended circuitconfigurations only. It is necessary, however, to provide low-cost andefficient coupling methods for both single-ended and differentialcircuits. Millimeter wave semiconductor circuit designs often make useof differential amplifier and output stage configurations to enable highgain and power efficiencies.

SUMMARY OF THE INVENTION

A waveguide interface comprising a support block configured to support aprinted circuit board assembly. An interface is coupled to an endportion of the support block and extends from the support block. Theinterface includes a slot positioned to receive at least a portion ofthe printed circuit board assembly and one or more holes positioned toreceive attachment devices to secure the interface to a waveguidecomponent. The support block and interface are molded as a monolithicdevice.

A method of forming a precision waveguide interface includes providing amold configured to form a support block configured to support a printedcircuit board assembly and an interface integrally formed to an endportion of the support block and that extends from the support block.The interface includes a slot configured to receive at least a portionof the printed circuit board assembly and one or more holes positionedto receive attachment devices to secure the interface to a waveguidecomponent. The provided mold is utilized to form the waveguide interfaceas a monolithic device.

This exemplary technology provides a number of advantages includingproviding a waveguide assembly, including a waveguide interface that maybe utilized at high operating frequencies. The waveguide assembly of thepresent technology incorporates, in one example, a waveguide interfacethat is molded as a single piece with nominal impact on the overallperformance of the waveguide assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-1C are side, front end, and top views, respectively, of anexemplary waveguide assembly including an exemplary waveguide interfacecoupled to a waveguide flange;

FIG. 2 is a cross sectional side view of the exemplary waveguideassembly shown in FIGS. 1A-1C;

FIG. 3 is a detailed rear view of the exemplary waveguide assembly shownin FIGS. 1A-1C;

FIG. 4 is a cross sectional top view of the exemplary waveguide assemblyshown in FIGS. 1A-1C;

FIG. 5A is a rear view of an exemplary waveguide flange;

FIG. 5B is rear view of the interface plate of the exemplary waveguideinterface shown in FIGS. 1A-1C;

FIG. 5C is a rear view of the exemplary waveguide flange shown in FIG.5A coupled to the exemplary interface plate shown in FIG. 5B;

FIGS. 6A-6C are a front view, side cross-sectional view, and an end viewof a support block of the exemplary waveguide interface shown in FIGS.1A-1C;

FIG. 7 is a perspective view of another exemplary waveguide interfacethat is molded as a single, monolithic device;

FIG. 8 is a top view of the exemplary waveguide interface shown in FIG.7;

FIG. 9 is a rear view of the exemplary waveguide interface shown in FIG.7;

FIG. 10 is a front view of the exemplary waveguide interface shown inFIG. 7;

FIG. 11 is a side cross-sectional view of the exemplary waveguideinterface shown in FIG. 9 along section A-A;

FIG. 12 is a top cross-sectional view of the exemplary waveguideinterface shown in FIG. 10 along section C-C;

FIG. 13 is a perspective view of the exemplary waveguide interface shownin FIG. 7 after machining processes to finalize the waveguide interface;

FIG. 14 is a rear view of the exemplary waveguide interface illustratedin FIG. 13;

FIGS. 15A-15D are respectively a top, side, end, and bottom view of anexemplary printed circuit board for use with the exemplary waveguideinterfaces of the present technology.

FIG. 16A is a top view of an exemplary transmitter printed circuit boardand launch transducer substrate assembly for use with the waveguideinterfaces of the present technology;

FIG. 16B is a top view of an exemplary receiver printed circuit boardand launch transducer substrate assembly for use with the waveguideinterfaces of the present technology;

FIGS. 17A and 17B are top and bottom views of an exemplary transmitterlaunch transducer substrate;

FIGS. 18A and 18B are top and bottom views of an exemplary receiverlaunch transducer substrate; and

FIG. 19 is a top view of another exemplary launch transducer substrateassembly for use with the waveguide interfaces of the presenttechnology.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1A, 1B, 1C, 2, 3, and 4, an example of a waveguideassembly 10 includes an exemplary waveguide interface 12(1) (shown inFIGS. 1A, 1C, 2, and 4), a printed circuit board assembly 14 (FIGS. 1A,1C, 2, 3 and 4) including a connector 16, a communication device 18(1)(shown in FIGS. 2, 3, and 4), a launch transducer 20(1) (shown in FIGS.2 and 4), and a waveguide flange 22 (shown in FIGS. 1A, 1C, 2, 3, and 4,is illustrated, although the waveguide assembly 10 could include othertypes and numbers of assemblies, devices, components, and/or otherelements in other configurations. As described below, the waveguideassembly 10 may be utilized for electromagnetic transmission andelectromagnetic reception. Both the transmission context and thereception context equally apply due to the Lorentz electromagneticreciprocity theorem. This exemplary technology provides a number ofadvantages including providing a waveguide assembly, including awaveguide interface that may be utilized at high operating frequencies.The waveguide assembly of the present technology incorporates, in oneexample, a waveguide interface that is molded as a single piece withnominal impact on the overall performance of the waveguide assembly. Themolded waveguide interface significantly reduces the overall cost of thewaveguide assembly.

Referring again to FIGS. 1A, 1B, 1C, 2, 3, and 4, the exemplarywaveguide interface 12(1) includes a support block 24(1) (shown in FIGS.1A, 1B, 2, and 3) coupled to an interface plate 26(1), although thewaveguide interface 12(1) may include other elements in otherconfigurations. The waveguide interface 12(1) operates in the waveguideassembly 10 to provide an interface between the waveguide flange 22 andthe communication device 18(1). In one example, as described furtherbelow, a waveguide interface may be utilized in the waveguide assembly10 that is constructed as a single, monolithic, metal injection-moldedstructure, such as the waveguide interface 12(2) illustrated in FIGS. 7,8, 9, 10, 11, 12, 13, and 14. The metal injection-molded waveguideinterface 12(2) advantageously provides a more economically producedwaveguide interface that may be utilized at high operating frequencies,with nominal impact on the performance of the waveguide assembly 10.

Referring again to FIGS. 1A, 1B, 1C, 2, 3, and 4, the support block 24(1) is configured to support the printed circuit board assembly 14having the connector 16, the communication device 18(1), and the launchtransducer 20(1) located on a surface thereof. The support block 24(1)extends in a plane orthogonal to the interface plate 26(1) and providesfor precise alignment of the printed circuit board assembly 14 with theinterface plate 26(1) and the waveguide flange 22.

The support block 24(1), in this example, is coupled to the interfaceplate 26(1) and the waveguide flange 22 by machine screws 28A (shown inFIGS. 1A, 1B, 1C, 2, and 3) and 28B (shown in FIGS. 1B, 2, and 3),although other types of fasteners may be utilized. Machine screws 28Aand 28B couple both the support block 24(1) and the interface plate26(1) to the waveguide flange 22 such that the interface plate 26(1) ispositioned between the support block 24(1) and the waveguide flange 22.In another example, as illustrated in FIGS. 7, 8, 9, 10, 11, 12, 13, and14, the support block 24(2) as shown in FIGS. 7, 8, 10, 11, 12 and 13and the interface 26(2) as shown in FIGS. 7-14 are molded as a singledevice and do not require any fastening elements to be coupled togetheras shown in FIGS. 7, 8, 11, 12, and 13.

Referring now to FIGS. 6A-6C, in one example, the support block 24(1)includes a counter-bored hole 30 that allows a machine screw, such asthe machine screw 28B (FIGS. 1B, 1C, 2, 3) to be inserted therein tocouple the support block 24(1) to the waveguide flange 22 and theinterface plate 26(1), as shown in FIG. 2, although the support block24(1) may include other fastening elements in other locations tofacilitate the coupling of the support block 24(1) to the interfaceplate 26(1) and waveguide flange 22. In one example, as described below,support block 24(2) and interface 26(2) are formed as a single,monolithic, part, such that no fastening elements are required onsupport block 24(2). As shown in FIGS. 6B and 6C, the support block24(1) optionally includes one or more support block guide pins 32 (alsoshown in FIG. 2) that aid in alignment of the support block 24(1) withthe interface plate 26(1) as discussed further below.

Referring now more specifically to FIGS. 1A, 1B, 1C, 2, 3, 4, and 5B,interface plate 26(1) is a circular interface plate, although otherconfigurations may be utilized for the interface plate 26(1). Theinterface plate 26(1) includes a rectangular slot 34(1) (shown in FIGS.1B, 2, 3, and 5B) located therethrough. The length of the rectangularslot 34(1) is configured to accept the printed circuit board assembly 14and the launch transducer 20(1) as illustrated in FIG. 2. The printedcircuit board assembly 14 and the rectangular slot 34(1) form a shortwaveguide segment 36 as shown in FIG. 2 within the rectangular slot34(1) when coupled.

Referring again to FIG. 5B, the interface plate 26(1) includes interfaceplate holes 38 which are sized and configured to receive machine screws28A and 28B (not shown in FIG. 5B), which secure the waveguide interface12(1) to the waveguide flange 22. The interface plate 26(1) may furtherhave interface plate guide pin holes 41(1) that may be aligned withsupport block guide pins 32 of the support block 24(1) to provideprecise alignment between the interface plate 26(1) and the supportblock 24(1). The interface plate 26(1) further includes guide pin holes41 that are configured to aid in alignment with the waveguide flange 22as described further below.

Referring now to FIGS. 7-14, another example of a waveguide interface12(2) for use in waveguide assembly 10 is illustrated. Waveguideinterface 12(2) interacts with waveguide flange 22 and operates in thesame manner as waveguide interface 12(1) except as illustrated anddescribed herein.

Waveguide interface 12(2) includes a support block 24(2) and aninterface 26(2) that are molded in an injection molding process as asingle, monolithic structure, although other types of molding techniquesmay be utilized. The waveguide interface 12(2), by way of example only,may be constructed of an injection moldable metal alloy such as Xyloy™M950, although other types of moldable metal alloys may be utilized toform the waveguide interface 12(2). The outer shape of the waveguideinterface 12(2) has been customized to allow for removal from a mold toenable the generation of the single monolithic structure, as discussedbelow. Specifically, the waveguide interface 12(2) includes a pluralityof draft angles as discussed below. The draft angles, discussed morespecifically below, provide for removal of the waveguide interface 12(2)without significant impact to the overall performance on the waveguideinterface 12(2) in the waveguide assembly 10. In particular, by way ofexample only, the propagation of millimeter wave energy into the openingof a waveguide flange connected to the waveguide interface 12(2) isaltered by less than one percent, which does not impact the overalloperating frequency range. Further, the waveguide cutoff frequency isaltered by less than one percent. Although various exemplary dimensionsare described below, it is to be understood that the dimensions may bevaried.

Support block 24(2) includes a top surface 100 (FIGS. 8, 10, 11, and 12)configured to support a printed circuit board assembly, such as printedcircuit board assembly 14, by way of example. By way of example, theprinted circuit board assembly may be attached to the top surface 100 ofthe support block 24(2) using an adhesive. The top surface 100 has sideedges 102 (shown in FIGS. 7, 8 and 12) that are tapered with a draftangle of approximately a 4 degree angle as illustrated in FIGS. 8 and12. As used herein throughout, the term “draft angle” refers to theamount of taper perpendicular to the parting line for the molded orcasted part described, as measured in degrees. The top surface 100 ofthe support block 24(2) has a width of approximately 0.400 inches at ajunction 104 (FIGS. 7, 8, 10, and 11) with the interface 26(2) and awidth of approximately 0.358 inches at an upper end edge 105 (FIGS. 7,8, and 12) thereof. The side edges 102 taper from the junction 104 tothe upper end edge at the draft angel of approximately 4 degrees.

The support block 24(2) includes sides 106 and end 108 as shown in FIGS.7 and 10 that taper downward from the top surface 100 with a draft angleof approximately 4 degrees, such that the support block 24(2) has awidth of approximately 0.315 inches at a lower end edge 110 shown inFIGS. 7 and 10. The support block 24(2) further includes a taperedbottom surface 112 at a draft angle of approximately 4 degrees as shownin FIG. 11, such that support block 24(2) has a height of approximately0.177 inches at the junction 104 with the interface 26(2) and a width ofapproximately 0.120 inches from the lower end edge 110 to the topsurface 100, although support block 24(2) may have other dimensions.

In this example, with the modified design with the draft angles anddimensions noted above, the support block 24(2) and the interface 26(2)can be molded as a single, monolithic device. The support block 24(2)extends from the interface 26(2) in a plane orthogonal to the interface26(2). The interface 26(2) is a circular interface configured to becoupled to a waveguide flange (not shown), such as waveguide flange 22,which by way of example may be a standard waveguide flange known in theart. The interface 26(2) includes a slot 34(2) (shown in FIGS. 7 and 11)configured to receive a portion of a printed circuit board assembly,including a launch transducer. In use, the slot 34(2) and an insertedprinted circuit board assembly form a short waveguide segment within thewaveguide interface 12(2) in the same manner as described with respectto the waveguide interface 12(1) above.

In this example, the slot 34(2) has width of approximately 0.400 inchesand a height of approximately 0.080 inches at the front opening asillustrated in FIG. 11. The slot 34(2) includes a tapered top surface113 with a draft angle of approximately 2.0 degrees from a front end113A to a rear end 113B of the slot 34(2). The slot 34(2) also includesa rear portion 114 with a tapered side 116 with a draft angle ofapproximately 4 degrees from a front end 115A to a rear end 115B of therear portion 114. The rear portion 114 meets with an opening in astandard waveguide flange.

The interface 26(2) includes outer edges 118 with a draft angle ofapproximately 2 degrees from a front end 119A to a rear end 119B of theouter edge 118 as shown in FIGS. 8 and 11. The interface 26(2) furtherincludes a number of interface holes 38(2) (shown in FIGS. 7, 9, 10, 11,12, 13, and 14) located therethrough. The interface holes 38(2) areconfigured to receive machine screws to facilitate coupling of thewaveguide interface 12(2) to a waveguide flange. The interface holes38(2) include tapered side walls 120 with a draft angle of approximately2 degrees from a front end 121A to a rear end 121B of the side walls 120to facilitate removal from the mold as shown in FIG. 11. The interfaceholes 38(2) are drilled or reamed and tapped with 4-40 threads, althoughother threads may be utilized, to result in a non-tapered hole in thefinished part as discussed below. The interface 26(2) also includesguide pin holes 41(2) (as shown in FIGS. 7, 9, 13, and 14) to providealignment with the guide pins of a standard waveguide flange.

The interface 26(2) also includes interface guide pins 122 (shown inFIGS. 7, 8, 9, 11, 12, 13, and 14) located on a rear surface of theinterface 26(2) that provide alignment between the interface 26(2) and awaveguide flange, although the interface 26(2) may have other devices inother locations to facilitate alignment between the interface 26(2) anda standard waveguide flange. In this example, the interface guide pins122 have a tapered shape with a draft angle of approximately 2 degreesfrom a front end 123A to a rear end 123B of the interface guide pins 122as shown in FIG. 8.

Referring now to FIGS. 13 and 14, the interface holes 38(2) and guidepin holes 41(2) are machined after the molding process to finalize thewaveguide interface 12(2). Specifically, interface holes 38(2) aretapped with an oversized tap so that the interface holes 38(2) areconfigured to accommodate plating therein. The interface holes 38(2) arefurther drilled or reamed, by example with a 4-40 thread, in order forthe interface holes 38(2) to accommodate screws for connecting theinterface 26(2). Further, the guide pin holes 41(2) are reamed to allowfor entry of a slip fit dowel pin when coupled to a standard waveguideflange. The waveguide interface 12(2) is further machined to remove allsharp edges resulting from the molding process.

Referring now to FIGS. 15A-15D, top, side, front end, and bottom viewsof the exemplary printed circuit board assembly 14 shown in FIG. 4 areillustrated, respectively. Printed circuit board assembly 14 includes acut out area 42 (shown in 15A and 15B) configured to receive thecommunication device 18(1) (not shown herein), such that thecommunication device 18(1) sits within the recessed cut out bottomsurface 44 and cut out side surfaces 46A and 46B (shown in FIG. 15B).Communication device 18(1) is coupled to the printed circuit boardassembly 14 using a conductive epoxy adhesive. Various conductive epoxyadhesives are known in the art and are not discussed herein.

The cut out area 42 as shown in FIGS. 4, 15A, 15B, 16A, and 16B, whichis a recessed portion of the printed circuit board assembly 14configured to receive the communication device 18(1), includes the cutout bottom surface 44 and cut out side surfaces 46A and 46B, ismetallized using standard printed circuit plating techniques. The cutout area 42 is copper and gold plated to maintain a continuouselectrical ground plane, although other conductive materials may beutilized. Printed circuit board assembly 14 further includes a topground plane area 48 (as shown in FIGS. 4, 16A, and 16B), a side groundplane area 50, a front ground plane area 52, and a bottom ground planearea 54 that are metallized using standard printed circuit platingtechniques, such that the top ground plane area 48, the side groundplane area 50, the front ground plane area 52, and the bottom groundplane area 54 are electrically contiguous. The top ground plane area 48,the side ground plane area 50, the front ground plane area 52, and thebottom ground plane area 54 are copper and gold plated, although otherconductive materials may be utilized. The top ground plane area 48 isfurther electrically contiguous with the cutout side surfaces 46A and46B and the cut out bottom surface 44 of the cut out area 42. The frontground plane area 52 provides an electrical ground plane in the localinterface region of the interface plate 26(1) or interface 26(2) andwaveguide flange 22.

Referring now to FIG. 16A, a top detailed view of the of the printedcircuit board assembly 14 shown in FIGS. 15A-15D along withcommunication device 18(1) and launch transducer 20(1), which provide atransmitter printed circuit board assembly, is shown. As shown in FIG.16A, the communication device 18(1), which is a transmittercommunication device, is affixed within the cut out area 42 of theprinted circuit assembly 14 and is positioned to abut the cut out areaside surface 46B adjacent to the launch transducer 20(1).

Low-frequency signal and power connections are supplied to thecommunication device 18(1) via a plurality of wire bonds 56 fromcorresponding wire bond pads 58, although other interconnectiontechnologies besides wire bond pads 58 may be utilized. High-frequencymillimeter wave connections are provided between the communicationdevice 18(1) and the adjacently positioned launch transducer 20(1) withlow-inductance wire or ribbon bonds 60(1), although other connectiontechnologies may be utilized. The printed circuit assembly 14 includes awidth defined by edges 62A and 62B.

Referring now to FIG. 16B, a top detailed view of the of the printedcircuit board assembly 14 along with the communication device 18(2) andlaunch transducer 20(2), which provide a receiver printed circuit boardassembly, is shown. The communication device 18(2), which is a receivercommunication device, is affixed within printed circuit assembly cut outarea 42, which is a recessed portion of the printed circuit boardassembly 14 configured to receive the communication device 18(1), andlocated to abut the cut out area side surface 46 adjacent to the launchtransducer 20(2).

Low-frequency signal and power connections from the printed circuitassembly 14 are provided to the communication device 18(2) via aplurality of wire bonds 56 from corresponding wire bond pads 58,although other interconnection technologies may be utilized.High-frequency millimeter wave connections are communicated between thecommunication device 18(2) and the launch transducer 20(2) withlow-inductance wire or ribbon bonds 60(2), although other connectiontechnologies may be utilized.

Referring again to FIG. 1A, the connector 16 utilized in the waveguideassembly 10 is a multi-pin connector that provides the lower-frequencyelectrical signals and power connections to the communication device18(1), although other types of connectors suitable to provide thelower-frequency electrical signals and power connections to thecommunication device 18(1) may be utilized. The connector 16 is locatedon the printed circuit assembly 14 at the rear of the waveguideinterface 12(1).

The communication device 18(1) is a highly integrated millimeter waveradio transmitter that is attached to the printed circuit assembly 14,although the communication device may alternatively be a highlyintegrated millimeter wave radio receiver, such as communication device18(2) shown in FIG. 16B. In one example, the communication device 18(1),18(2) is a silicon germanium (SiGe) chip, although gallium arsenide(GaAs), complimentary metal oxide semiconductor (CMOS), or othersemiconductor chips may be utilized for the communication device 18(1),18(2). The communication device 18(1), 18(2), by way of example only,may be configured to work with a 60 GHz millimeter wave launchtransducer 20(1), 20(2). The communication device 18(1) is a balancedoutput connection at the transmitter output terminal, whilecommunication device 18(2) is an unbalanced input connection to thereceiver input terminals. In one example, the communication device18(1), 18(2) is protected from the environment by a protective cover 64as shown in FIGS. 1A and 1C. The protective cover 64 is made of plastic,although the protective cover 64 may be constructed from othernon-conductive materials may be utilized.

Referring again to FIG. 16A, in this example the printed circuit boardassembly further includes the launch transducer 20(1), which acts as atransmitter. In one example, the waveguide assembly 10 utilizes a 60 GHzmillimeter wave launch transducer 20(1) and enabled communication device18(1), although the present technology is not limited thereto.Additionally, the launch transducer 20(1) is implemented with matchingbalanced transmission line terminals to efficiently accepthigh-frequency energy from the communication device 18(1). Launchtransducer 20(1) is located precisely at the midpoint between widthedges 62A and 62B of the printed circuit assembly 14. Additionally, thelaunch transducer 20(1) has a width dimension Y_(t) that is preciselymatched to the opening of the waveguide flange dimension, as discussedbelow.

FIGS. 17A and 17B show top and bottom views of the transmitter launchtransducer 20(1). As shown in FIGS. 17A and 17B, the launch transducer20(1) is composed of low-loss substrate 66 which has a top metallizationpattern and bottom metallization pattern. In this example, the low-losssubstrate 66 is composed of fused silica (silicon dioxide) and is 254micrometers (μm) thick, although other low-loss substrate materials andother material thickness values may be utilized. The metallizationpattern is substantially composed of vacuum deposited gold metal fromvacuum deposition techniques, although other deposition methods may beutilized.

The top metallization pattern of the transmitter launch transducer 20(1)is composed of a first pair of transmission line sections 68A and 68B asshown in FIG. 17A. The first pair of transmission line sections 68A and68B are implemented over a ground plane 70 on the bottom side of thelow-loss substrate 66. The first pair of transmission line sections 68Aand 68B couple energy from the communication device 18(1) via bond wires60(1), as shown in FIG. 16A, or other means to a second pair oftransmission line sections 72A and 72B as shown in FIG. 17A. The firstpair of transmission line sections 68A and 68B are implemented to matchthe output impedance of the communication device 18(1) and the bondwires 60(1), as shown in FIG. 16A, in a balanced configuration.

The second pair of transmission line sections 72A and 72B are locatedover a clear substrate section (with no ground plane on the bottom sideof the low-loss substrate 66 in this section as shown in FIG. 17B) andprovide energy from the first pair of transmission lines 68A and 68B toa pair of corresponding transducer elements 74A and 74B as shown in FIG.17A. The second pair of transmission line sections 72A and 72B areimplemented to match the input impedance of the transducer elements 74Aand 74B.

The transducer elements 74A and 74B are configured to providesubstantial energy propagation in a direction parallel to the low-losssubstrate 66 and away from the second pair of transmission line sections72A and 72B, thereby forming an end-fire propagation pattern into anopening in the waveguide flange opening. The launch transducer 20(1) hasa width dimension, Y_(t) (shown in FIG. 17B), that is matched to beinserted into the standard waveguide flange opening having the “b”dimension, as shown in FIG. 5A, described below. In one example, Y_(t)is 1.80 mm and the value of X_(t) (shown in FIG. 17B) is 2.87 mm,although other values for these dimensions are contemplated. Although anexemplary configuration for the launch transducer 20(1) is illustratedand described, alternative configurations may be utilized. By way ofexample, in another embodiment, launch transducer 20(1) may include avariation of a dipole with a parasitic element as illustrated in FIG.19.

Referring again FIG. 16B, in another example the printed circuit boardassembly 14 includes the launch transducer 20(2), which acts as areceiver. In one example, the waveguide assembly 10 utilizes a 60 GHzmillimeter wave launch transducer 20(2) and enabled communication device18(2), although the present technology is not limited thereto. Thelaunch transducer 20(2) is implemented with matching unbalancedtransmission line terminals to efficiently deliver high-frequency energyto the communication device 18(2). The launch transducer 20(2) islocated precisely at the midpoint between printed circuit assembly 14width edges 62A and 62B The launch transducer 20(2) has a width that isprecisely matched to the to the opening of the waveguide flangedimension, as discussed below.

FIGS. 18A and 18B show top and bottom views of a receiver launchtransducer 20(2). Receiver launch transducer has dimensions X_(r) andY_(r) as shown in FIG. 18B in a similar manner as described with respectto FIG. 17B above. The launch transducer 20(2) is composed of a low-losssubstrate 76 which has a top metallization pattern and bottommetallization pattern. In this example, the substrate 76 is composed ofalumina (aluminum oxide) and is 127 micrometers (μm) thick, althoughother low-loss substrate materials and other material thickness valuesmay be utilized. The metallization pattern is substantially composed ofvacuum deposited gold metal using vacuum deposition techniques or otherappropriate methods.

In this example, the top metallization pattern includes a transmissionline center conductor 78 (FIG. 18A) that traverses a length over aground plane 80, which is located on the bottom side of the low-losssubstrate 76. Beyond the position of ground plane 80, the transmissionline center conductor 78 continues and is positioned over a bottom sidetransmission line 82 (FIG. 18B). The transmission line center conductor78 and the bottom side transmission line 82 together are coupled totransducer elements 84A (FIG. 17A), 84B (FIG. 17A), 84C (FIG. 17B), and84D (FIG. 17B). The transducer elements 84A and 84B and 84C and 84D,respectively, form dual element dipoles and are configured to provide adirectional propagation pattern in a direction parallel to the low-losssubstrate 76 and away from the transmission line center conductor 78 andthe bottom side transmission line 82, thereby forming an end-firepropagation pattern into a waveguide flange opening, as discussed below.

The unbalanced input circuit configuration is composed of a groundconnection 86 and the transmission line center conductor 78. The groundconnection 86 (FIG. 18A) is electrically connected through the low-losssubstrate 76 and facilitated by metalized plating through holes (alsoknown as vias) 88A and 88B, thereby forming a low-inductance connectionto the ground plane 80 on the bottom side of the low-loss substrate 76.In one example, the diameter of via holes 88A and 88B is 127 micrometers(μm) with gold metallization formed on the inner walls, although otherdimensions and material selections are contemplated. FIG. 19 illustratesanother exemplary launch transducer that may be utilized with theexamples of the present technology disclosed herein.

Referring again to FIGS. 1A, 1B, 1C, 2, 3, and 4, the waveguideinterface 12(1) is coupled to the waveguide flange 22. The waveguideflange 22 is a standard waveguide flange known in the art. As shown inFIGS. 2 and 4, the waveguide flange 22 includes a waveguide flangeopening 90 that may be aligned with the rectangular slot 34(1) in theinterface plate 26(1) of the waveguide interface 12(1). The waveguideopening 90 is rectangular having an “a” dimension (FIGS. 2 and 5A)representing the H-field for a rectangular waveguide. Precise alignmentof interface plate 26(1) with the standard waveguide flange 22 isfacilitated by the standard waveguide flange guide pins 92 (shown inFIGS. 1A, 1B, and 3) inserted into guide pin holes 41(1) as shown inFIG. 3 contained within interface plate 26(1). FIG. 5C illustrates thewaveguide flange 22 coupled to the interface plate 26(1), wherein theinterface plate 26(1) is aligned to the waveguide flange assembly 22with the rectangular slot 34(1) of the interface plate 26(1) overlappingwith the waveguide flange opening 90 with the standard waveguide flangeguide pins 92 inserted into the guide pin holes 41(1).

As shown in FIG. 5A, the waveguide flange 22 includes the waveguideopening 90 positioned substantially in the center of the circularwaveguide flange 22. In particular, the waveguide opening 90 isrectangular having an “a” dimension representing the H-field and a “b”dimension representing the E-field for a rectangular waveguide. In thisexample, the dimensions of the waveguide opening 90 are configured to beutilized for the frequency range of 50 to 75 GHz, whereby the dimensionsare defined by what is known categorized in the art as WR-15 or inmilitary standard MIL-DTL-85/3C as M85/3-018. By way of example only,for the 50 to 75 GHz standard waveguide frequency range, also known asV-band, the “a” dimension is approximately 3.76 mm and the “b” dimensionis approximately 1.88 mm, although other “a” and “b” dimensions may beutilized depending on the type of application and/or the frequency rangedesired. Precise alignment of interface plate 26(1) with the standardwaveguide flange 22 is facilitated by the standard waveguide flangeguide pins 92 inserted into guide pin holes 41(1) contained withininterface plate 26(1), as discussed above.

An example of the operation of the waveguide assembly 10, includingeither waveguide interface 12(1) or waveguide interface 12(2) will nowbe described with respect to FIGS. 1A, 1B, 1C, 2, 3, 4, 5A, 5B, 5C, 6A,6B, 6C, 7, 8, 9, 10, 11, 12, 13, 14, 15A, 15B, 15C, 15D, 16A, 16B, 17A,17B, 18A, 18B, and 19. It should be noted that the detailed descriptionof the transmitter waveguide interface operation applies equally to thereceiver waveguide interface with the direction of the millimeter wavetransduction and energy reversed. Those of ordinary skill in the artwill realize that both the transmission context and the receptioncontext equally apply due to the Lorentz electromagnetic reciprocitytheorem. It is also noted that although the operation is discussed withrespect to waveguide interface 12(1), the operation of waveguideinterface 12(2) is substantially the same as waveguide interface 12(1).

Critical to the high efficiency and operation of the waveguideinterfaces 12(1) and 12(2) is to facilitate propagation of millimeterwave energy into standard waveguide flange opening 90 and also restrictenergy losses as the conducted electrical energy moves from thecommunications device 18(1) through the high frequency wire bonds 60(1)to the first pair of transmission lines 68A and 68B. The short waveguidesegment 36 as shown in FIGS. 2 and 11 is defined between the rectangularslot 34(1) of interface plate 26(1), or interface 26(2), and the upperground plane surface 48 of the printed circuit board assembly 14. Theprinted circuit board assembly 14 also has contiguous copper plating atside ground plane area 50 and front ground plane area 52, which form thelower portion of the short waveguide segment 36.

The waveguide cutoff frequency is the frequency at which all frequenciesbelow the cutoff frequency are substantially attenuated. Equation [1],derived from the Helmholtz equation for electromagnetic waves, providesthe waveguide cutoff frequency for rectangular waveguide with aninternal H-field “a” dimension and internal E-field “b” dimension.

$\begin{matrix}{\omega_{c} = {c\sqrt{\left( \frac{n\;\pi}{a} \right)^{2} + \left( \frac{m\;\pi}{b} \right)^{2}}}} & \lbrack 1\rbrack\end{matrix}$

In equation [1], ω_(c), is radian frequency, c is the speed of light, ais the H-field rectangular waveguide dimension, b is the E-fieldrectangular waveguide dimension, and n and m represent the waveguidemode numbers. The dominant waveguide mode is used to determine waveguidecutoff and is known in the art as transverse electric mode 1,0(TE_(1,0)) where n=1 and m=0. With n=1 and m=0, the only variableremaining is the waveguide H-field “a” dimension.

In one example, for the standard waveguide flange 22, the “a” dimensionis 3.76 mm which yields a cutoff frequency of 39.9 GHz, well below theintended operating frequency range of standard waveguide flange 22,which is 50 to 75 GHz. However, it is desired to substantially attenuatethe transduction of energy over the operating frequency range of thewaveguide interface in the short waveguide segment 36.

The H-field dimension of short waveguide segment 36 is shown as the “a′”dimension in FIG. 2. In one example, the “a′” dimension is approximately0.98 mm (980 μm). Setting a in equation to 0.98 mm with dominant mode(n=1 and m=0) yields a cutoff frequency of 153 GHz, well above theintended operating range of the waveguide interface. There will beslight variations of the cutoff frequency as the dimension “a′” variesas a function of the thickness of the printed circuit board assembly 14and the effective dimension “a′” varies due to the dielectric loadingproperties and thickness variation of launch transducer 20(1). However,with all variations taken into account, the minimum waveguide cutofffrequency for either the transmitter waveguide interface or the receiverwaveguide interface is greater than 120 GHz. By establishing shortsegment waveguide 36 cutoff frequency well above the operating frequencyrange of the waveguide interface, maximum energy is provided to thestandard waveguide opening 90.

Accordingly, this exemplary technology provides a number of advantagesincluding providing a waveguide assembly including a waveguide interfacethat may be utilized at high operating frequencies. The waveguideassembly of the present technology incorporates, in one example, awaveguide interface that is molded as a single piece, with nominalimpact on the overall performance of the waveguide assembly.

Having thus described the basic concept of the disclosed technology, itwill be rather apparent to those skilled in the art that the foregoingdetailed disclosure is intended to be presented by way of example only,and is not limiting. Various alterations, improvements, andmodifications will occur and are intended to those skilled in the art,though not expressly stated herein. These alterations, improvements, andmodifications are intended to be suggested hereby, and are within thespirit and scope of the disclosed technology. Additionally, the recitedorder of processing elements or sequences, or the use of numbers,letters, or other designations therefore, is not intended to limit theclaimed processes to any order except as may be specified in the claims.Accordingly, the invention is limited only by the following claims andequivalents thereto.

What is claimed is:
 1. A waveguide interface comprising: a monolithicmolded device comprising a support block configured to support a printedcircuit board assembly and an interface coupled to an end portion of thesupport block and extending from the support block, the interface havinga slot positioned to receive at least a portion of the printed circuitboard assembly and one or more holes positioned to receive attachmentdevices to secure the interface to a waveguide flange.
 2. The waveguideinterface of claim 1, wherein the support block and the interface areformed from a moldable metal alloy.
 3. The waveguide interface of claim1, wherein the support block and interface comprise a plurality of draftangles along one or more surfaces of the support block and the interfaceto allow for removal from a mold.
 4. A waveguide assembly comprising: amonolithic molded waveguide interface comprising a support block havinga printed circuit board assembly affixed thereto and an interfacecoupled to an end portion of the support block and extending from thesupport block, the interface having a slot positioned to receive atleast a portion of the printed circuit board assembly; a launchtransducer comprising one or more transmission lines in a first portionof the launch transducer and at least one transducer element coupled tothe one or more transmission lines in a second portion of the launchtransducer, wherein the at least one transducer element is configured topropagate millimeter wave frequency signals; a communication devicecoupled to the printed circuit board assembly, wherein the launchtransducer is positioned adjacent to and coupled to the communicationdevice; and a waveguide flange coupled to the interface of the waveguideinterface, the waveguide flange having a waveguide opening, wherein theinterface has one or more holes positioned to receive attachment devicesto secure the waveguide flange to the interface.
 5. The waveguideassembly of claim 4, wherein the interface is positioned flush againstthe waveguide flange such that a narrow dimension of the slot within theinterface is orthogonal to an H-field dimension of the waveguide flange.6. The waveguide assembly of claim 4, wherein the first portion of thelaunch transducer is positioned within the slot within the interfacesuch that the slot prevents energy from the transmission line from beingemitted toward the printed circuit board or the waveguide opening andallows energy to pass from the at least one transducer element into thewaveguide opening.
 7. The waveguide assembly of claim 4, wherein thecommunication device is configured to transmit and receive millimeterwave signals.
 8. The waveguide assembly of claim 4, wherein the launchtransducer further comprises a low-loss dielectric material withdeposited metallization.
 9. The waveguide assembly of claim 4, whereinthe second portion of the launch transducer is positioned within thewaveguide opening.
 10. The waveguide assembly of claim 4, wherein thelaunch transducer is positioned near a top surface of the support blockmidway between opposing edges of the top surface of the support block.11. The waveguide assembly of claim 4, wherein the communication deviceis positioned within a recess in the printed circuit board such that thefirst portion of the launch transducer is at a predetermined heightwithin the slot within the interface.
 12. The waveguide assembly ofclaim 4, wherein the launch transducer is positioned to provide maximumenergy propagation along a central axis of the waveguide interface. 13.The waveguide assembly of claim 4, wherein the launch transducer has anoperating frequency range between 57 GHz to 66 GHz.
 14. The waveguideassembly of claim 4, wherein the slot within the interface comprisessidewalls having a draft angle of about two degrees, wherein the draftangle impacts transmission of millimeter waveguide energy into thewaveguide opening by less than one percent.